1、1長安長安PSA焊裝過程質量控制焊裝過程質量控制CAPSA Welding Process Quality Control21. 長安長安PSA焊焊裝過程質量控制裝過程質量控制 CAPSA Welding Process Quality Control離線抽檢Offline spot-check破壞性檢查Destructive inspection在線檢測Online check不接受缺陷、不制造缺陷、不傳遞缺陷不接受缺陷、不制造缺陷、不傳遞缺陷Not accept defect, Not make defect, Not pass defect質量目標質量目標Quality target23

2、2. 在線檢測在線檢測Online check2.1 質量門質量門Quality gate(PQG)： 為控制本工序質量問題流出而設定的質量檢查工位 It is a station to control quality for current process area and prevent defect from passing to next process area342.2 質量門檢查內容質量門檢查內容PQG check items： 一、二級外觀面監(jiān)控：100%檢查 Aspect monitoring: 100% check 焊點監(jiān)控：外觀焊點100%檢查，不允許外觀嚴重扭曲變形、毛

3、刺、焊渣、穿孔等焊接缺陷出現(xiàn) Welding spot monitoring: 100% check aspect welding spots, not allow deformation, burrs, welding spatter, perforation defects 嵌入件監(jiān)控：100%檢查嵌入件有無漏裝并進行畫筆確認 Insert part monitoring: 100% check insert part exist or not with marking confirmation. 螺柱/螺母/螺釘/T型釘監(jiān)控：使用膠錘敲擊做100%強度檢查，同時目視數(shù)量是否符合工藝文件要

4、求 Stud/nut/screw/T-stud monitoring: 100% inspection by rubber hammer, check the quantity also MIG/MAG焊監(jiān)控：100%目視確認焊縫位置、外觀是否符合標準要求 MIG/MAG welding monitoring: 100% check the positon and aspect conformity of welding seam 激光焊監(jiān)控：100%檢查焊縫質量及位置 Laser welding monitoring: 100% check laser welding seam qualit

5、y and position42. 在線檢測在線檢測Online check52.2 質量門檢查內容質量門檢查內容PQG check items： 激光釬焊監(jiān)控：按照激光釬焊外觀標準要求全檢外觀 Laser brazing monitoring: 100% check the welding seam aspect according to related standard 包邊監(jiān)控：對包邊外觀進行全檢 Hemming monitoring: 100% check hemming aspect 鉚接監(jiān)控：對外觀進行全檢，同時需要手工進行確認鉚接是否牢固（手推鉚接零件無松動） Clinching

6、 monitoring: 100% check aspect and clinching strength by hand(push the part and not move) 擰緊扭矩監(jiān)控：除翼子板外，使用扭矩扳手定扭，翼子板按照10%比例使用扭矩扳手定扭。此外亦需要監(jiān)控螺栓數(shù)量及位置是否正確。 Torque monitoring: Except fenders, check the torque by torque wrench, 10% check the torque for fenders. Besides, check the quantity and position of s

7、crew. 其他動態(tài)監(jiān)控項目：如臨時增加需做特別監(jiān)控的內容 Other dynamic monitoring items: such as temporary monitoring item with specific purpose 52. 在線檢測在線檢測Online check62.3 質量門圖片展示質量門圖片展示PQG Pictures：門總成質量門Door PQG側圍質量門Bodyside PQG頂蓋激光釬焊質量檢查Roof laser brazing quality inspection激光焊質量檢查Laser welding quality inspection后地板質量門Rea

8、r unit PQG62. 在線檢測在線檢測Online check72.4 車身幾何尺寸精度在線檢測車身幾何尺寸精度在線檢測 Framing body geometry online measuring 動態(tài)測量重復精度Dynamic measuring repeatability： 0.2mm, 6sigma: 0.3429mm態(tài)態(tài)測量重復精度：測量重復精度： 0.2mm, 6sigma: 0.3429mm測量報告Measuring report機器人式柔性在線測量系統(tǒng)Robot flexible online measuring system固定式在線測量系統(tǒng)Fixed online m

9、easuring system7測量位置超過80個，計算點超過200個More than 80 measuring points and 200 calculation points2. 在線檢測在線檢測Online check82.5 白車身間隙面差在線檢測白車身間隙面差在線檢測 BIW gap & flushness online measuring 動態(tài)測量重復精度Dynamic measuring repeatability ： 間隙Gap： 0.2mm, 6sigma: 0.3429mm 面差Flushness： 0.2mm, 6sigma: 0.3429mm 測量范圍Mea

10、suring range 間隙Gap： 120mm 面差Flushness： -15+15mm8固定式間隙面差在線測量系統(tǒng)Fixed gap & flushness online measuring system測量位置超過35個，計算點超過100個More than 35 measuring points and 100 calculation points2. 在線檢測在線檢測Online check92.5 白車身間隙面差在線檢測白車身間隙面差在線檢測BIW gap & flushness online measuring 特點Features：u節(jié)省人力Save man

11、poweru更高的測量精度、測量重復性，有效避免手工測量誤差 Better accuracy, better repeatability, avoid manual mistakesu可以測量一些手工無法測量的數(shù)據(jù)，如左右側的相對差值 Add some specific checks not feasible by hand (Right/left side consistency)u可以100%測量監(jiān)控所有間隙面差控制點 100% online measuring all gap & flushness control pointsu白車身可以在移動中測量，不需要停下車輛 Measu

12、rement in the flow, not necessary to stop the vehicleu平均一次完整的測量時間（測量+處理測量值+顯示結果）：5秒鐘 Mean complete measurement time (Grabbing + processing of measurements + display of results): 5 seconds 9移動中測量Measurement in the flow測量分析Measuring analysis測量報告Measuring report2. 在線檢測在線檢測Online check102.5 白車身間隙面差在線檢測白

13、車身間隙面差在線檢測BIW gap&flushness online measuring 測量績效Performance10測量可靠性提升Measuring reliability improving間隙面差在線測量一次通過率對標FTT benchmark for gap & flushness online measuring2. 在線檢測在線檢測Online check112.6 在線檢具測量在線檢具測量Online checking fixture112. 在線檢測在線檢測Online check123.1 非破壞性質量檢查非破壞性質量檢查Non-destructive

14、quality inspection 分總成每天抽檢34臺車，車身總成每天抽檢5臺車 34 subassemblies & 5 framing bodies per day3. 離線抽檢離線抽檢Offline spot check非破壞性檢查支架Non-destructive checking fixture非破壞性焊點質量檢查Non-destructive spot welding quality check 12沖鉚連接質量檢查Clinching quality inspection133.1 非非破壞性質量檢查破壞性質量檢查Non-destructive quality insp

15、ection螺柱/螺母/螺釘/T型釘焊接接檢測 Stud/nut/screw/T-stud welding quality inspection 涂膠直徑、長度及位置監(jiān)控 Glue diameter, length and position check 133. 離線抽檢離線抽檢Offline spot check143.1 非非破壞性質量檢查破壞性質量檢查Non-destructive quality inspection焊點質量超聲波檢測焊點質量超聲波檢測Welding quality ultra-sonic inspection：按非破壞性檢查頻率對不可敲焊點進行檢查；另外每月對全車所有

16、焊點再進行一次全檢。According to non-destructive inspection frequency, inspect welding spots which are unable to be checked by manual tool; besides, full inspection of all BIW welding spots per month14焊點檢查焊點檢查Welding spots inspection：利用發(fā)射一個極短的高頻超音波透過焊點計算能量的飛行距離及衰減情況來評估焊接品質Launch a very short high frequency ul

17、trasonic to penetrate welding spot and then calculate the flight distance and attenuation of energy so as to evaluate weld quality3. 離線抽檢離線抽檢Offline spot check15前縱梁Front side members前地板Front unit后地板Rear unit地板總成Underbody儀表板DashboardCMM車身Framing body側圍總成Bodyside前側圍內板Front bodyside inner后側圍內板Rear body

18、side inner激光在線測量激光在線測量Laser online measuring調整線MFL機蓋Hood尾門/行李箱Tailgate/Trunk前門內板Front door inner前門總成Front door后門內板Rear door inner后門總成Rear door翼子板Fenders間隙面差在線測量間隙面差在線測量Gap & flushness online measuringCMMCMMCMMCMMCMMCMMCMMCMMCMMCMMPCFPCFPCFCMMPCFGauge3.2 三坐標三坐標&PCF測量測量CMM and PCF measuring CM

19、M每周各抽測4套 4 sets per week for CMM153. 離線抽檢離線抽檢Offline spot check163.2 三坐標三坐標&PCF測量測量 CMM and PCF measuringCMMCMMCMMCMMCMMCMMCMMCMMCMMCMMPCFPCFPCFPCF163. 離線抽檢離線抽檢Offline spot checkCMM173.3 三坐標測量三坐標測量CMM17測量點超過5000個More than 5000 measuring points3. 離線抽檢離線抽檢Offline spot check183.4 PCF（開閉件總成檢具（開閉件總成檢

20、具 ）測量測量 PCF(checking fixture for closure assembly parts) measuring： 每天抽檢1臺車 1 set/day門蓋幾何尺寸測量檢具 Doors & hood & trunk geometry checking fixtures測量工具Tools面差測量 Flushness measuring間隙測量Gap measuring孔位偏差測量 Position of holes門總成密封間隙測量Sealing gap of doors包邊厚度測量Hemming thickness183. 離線抽檢離線抽檢Offline sp

21、ot check193.5 白白車身全車身全尺寸尺寸Podium離線離線測量測量 BIW overall dimension Podium offline measuring 每周一次。監(jiān)控內容不僅包括EDIXIA 在線監(jiān)控的內容，還包括總裝的部分裝配尺寸 One time per week. Not only include EDIXIA online measuring points, but also include dimension for some assembly parts mounting 19前大燈與翼子板間隙面差測量Gap & flushness between

22、headlamp and fender機罩與前保險杠、翼子板的間隙面差測量Gap & flushness between front bumper and hood & fender尾燈及附屬尾燈與側圍、行李箱的間隙面差測量Gap & flushness between tail lamps and bodyside & trunk測量位置超過160個，計算點超過250個More than 160 measuring points and 250 calculation points3. 離線抽檢離線抽檢Offline spot check門框密封間隙測量Sealing gap of doors204.1 焊接質量破壞性檢查焊接質量破壞性檢查Welding quality destructive inspection4. 破壞性檢查破壞性檢查Destructive inspection全車焊點合格率Pass rate 99%量產(chǎn)前Before mass production： 試裝期間總計破壞性檢查約30臺車用于監(jiān)控及改善焊接質量 About 30 BIWs for destructive inspection in order to monitor and improve welding quality durin